Multi-ply carton construction



Oct. 13, 1959 J. D. MILLER MULTI-PLY CARTON CONSTRUCTION 3 Sheets-Sheet1 Filed March 3, 1958 INVENTOR Kim/12 Mare BY jaw-z ORNEYS Oct. 13 1959J. D. MILLER MULTI-PLY CARTON CONSTRUCTION 3 Sheets-Sheet 2 Filed March3, 1958 Oct. 13, 1959 J. D. MILLER MULTI-PLY CARTON CONSTRUCTION 3Sheets-Sheet 3 Filed March 3, 1958 INVENTOR \AWA/a Mare BY 2W1; K.-

United States Patent MULTLPLY CARTON CONSTRUCTION John D. Miller,Toledo, Ohio, assignor to Owens-Illinois Glass Company, a corporation ofOhio- Applicati'on March 3, 1958, Serial No. 718,581

4 Claims. (Cl. 229- 15) The present invention relates to a cartonconstruction which is formed of a plurality of plies of the material ofconstruction and is designed to include integral partitioning for thepurpose of providing a plurality of cells.

Producers of canned and bottled beverages have found that the marketingof such items is enhanced by putting up such items in six-pack form. Theusual six-pack consists of six bottles or cans of the product containedin a Wrap or light weight box formed of chipboard or cardboard, andwhich usually includes handles to permit such items to be convenientlycarried by the ultimate consumer. These six-packs are conventionallyshipped from the manufacturer to the wholesaler and to the dealer inwooden boxes of a size to contain four such six-packs. Obviously, theseWooden boxes are expensive, and economically necessitate that thesewooden boxes be reused, and, accordingly, they must be shipped back tothe manufacturer. There have been previous attempts in the industry inmany instances to replace wooden boxes by cartons formed of relativelyinexpensive materials, of which corrugated paperboard is the mostpopular example. Unfortunately, these previous attempts either failedwith respect to the strength requirements, have had to resort toauxiliary reinforcing elements of the more ocnventional materials suchas wood and the like, or have been of extremely complicated design,which increases the cost of manufacture and frequently involvesconsiderable effort in assembly.

Accordingly, it is an object of this invention to provide a cartonconstruction of a relatively inexpensive material of construction, whichcarton is of exceptional strength.

It is another object of this invention to provide such a carton whichincludes partitions which are integrally a part of the main portion ofthe carton.

It is another object of this invention to provide such a carton which iscomposed of many plies of the material of'construction, yet is ofrelatively simple design and thereby involves a minimum of waste of thematerial of construction, and is capable of assembly with a minimum ofeffort.

It is also an object of this invention to provide such a carton whichdoes not require any auxiliary reinforcing elements of the more rigidmaterials and does not require any auxiliary fastening arrangements tohold same in assembled form.

These and many other objects of the invention will become apparent tothose skilled in the art from the following detailed description, takenin conjunction with the annexed sheets of drawings, on which there ispresented for purposes of illustration only, an embodiment of theinvention.

In the drawings:

Fig. 1 is aperspective view of the completed carton construction.

Fig. 2 is a plan view of a blank used in forming one component of thecarton of this invention.

Fig. 3 is a perspective view of the blank shown in Fig. 2 inanintermediate stage in the erection thereof.

- thereby define side walls of the final carton.

2,908,436 Patented Oct. 13,, T1959 Fig. 4 is a perspective view showingthe final form of the erection of the element shown inFigs. 2 and 3.

Fig. 5 is a plan view of the blank which is used in forming the secondcomponent of the carton of this invention.

Fig. 6 is a perspective view illustrating how the blank of Fig. 5 isfolded andcombined with the element of Fig. 4 to produce the completedcarton shown in Fig. l.

Basically, the carton of the present invention comprises a firstreceptacle defined by a bottom wall, walls upstanding from the perimeterof the bottom wall and internal partitions, a reinforcing element formedof a linear series of foldable panels, one of which is adapted tooverlie the bottom wall, two pairs of which are adapted to encloseopposed upstanding walls, another pair of which is adapted tocooperatively reinforce the bottom wall, and a last pair being adaptedto project upwardly through slits provided in the bottom wall formersand interfit with the internal partition to thereby yield aninterlocked, internally partitioned carton, in which all elementsthereof are formed of multiple plies.

Referring now more specifically to the drawings, there is shown in Fig.1 the completed carton 10 of the present invention. The cartoncomprises, in general, a bottom wall 11, opposite upstanding side walls12 and 13, opposed upstanding end walls 14 and 15, and internalupstanding normally disposed partitions 16 and 17. The walls 14 and 15are provided with cut-outs 18 and 19, respectively, which serve asconvenient hand holds. The carton 10 is erected from two elements formedof relatively stiif, sheet-like material, for instance, corrugatedpaperboard. These two elements 20 and 50 are shown, respectively, inknock-down blank form in Figs. 2 and 5.

The blank 20 in Fig. 2 is composed of a linear series of relativelyfoldable rectangular panels 21, 22, 23, 24, 25, 26, and 27, separated byscore lines 28 in parallel spaced relationship. The centermost panel 24is provided with a pair of normally intersecting slits 29 and 30. A flap31 extends axially from each end of the pairs of panels 22, 23, and 25,26, and is: separated from the associated panels by a fold line 32.Score line 23 extends across the score line 32 to divide the flap 31into two equal parts 31a and 31b, and lends foldability thereto for apurpose explaned hereinafter. Each portion 31a and 31b is provided witha notch 35 in its outermost free edge, which is so positioned that thenotches in adjoining portions will be in registry when the blank isfolded about fold line 28 to bring the associated panels intoface-toface relationship.

A flap or tab 40 extends axially from the panel 21 and is foldablysecured thereto by means of score line 41. The flap or tab 40 isprovided with opposed recesses 42 which define shoulders 43 whichprovide a self-locking feature. A slot 44 traverses the fold line 41between panels 21 and the flap or tab 40, and is in alignmentwith slit30. A similar flap or tab 46 extends axially from the other endmostpanel 27 and is separated therefrom by a fold line 47. This flap or tablikewise possesses opposed recesses 47 which define opposed shoulders 48for a locking feature. A slot 49 traverses the fold line 47 and is inalignment with slit 30.

The blank just described is erected into carton configuration in themanner shown in Fig. 3. The central panel 24 becomes a ply of theultimate bottom wall 11 (Fig. 1). Side panels 25 and 26 are folded intoface-toface relationship and into a plane normal to panel 24 to The foldline 28 between the side panels 25 and 26 becomes the upper edge of theside wall. The panel 27 is then folded- Ieversely beneath the panel '24and spans the distance from the side wall to the slit 29. The flap ortab 46 can then be inserted in the slit 29 and projected upwardly into aa position normal to the panel 24. The portion of the slot 49 within thepanel 27 will register with the slit 30, while the portion of the slot49 in the flap or tab 46 will intersect therewith, but willproject'upwardly in; the plane of the flap or tab46. In identicalfashion, the panels 22 and 23 are folded into face-to-face relationshipto-form an opposite side wall, the panel 21 is reversely folded beneaththe panel 24, and the tab or flap 40 introduced into the slit 29 toproject upwardly intoface-to-face relationship with the flap or tab 46.The flaps 31' will have their parts 31a and 31b in flush relationship,and these are folded inwardly in a plane normal to the side wall definedby the panels 25, 26, and 22, 23, respectively. There will thus bedefined end walls for the carton which are composed of two plies (31a,31b) which have hand holds therethrough by reason of the edge-to-edgemeeting of the panels having notches 35 in the free edges.

The construction of the cartonof this invention at this stage is shownin Fig. 4, wherein it can be seen that the side walls, end walls, bottomwall, and partitions are formed of two plies of the material ofconstruction. As may further be seen, the end walls formed by theinturned flaps 31 will have a tendency to unfold. If desired, maskingtape or the like may be used to hold them together in edge-to-edgerelationship. This is not absolutely necessary, however, inasmuch as thesecond component of the receptacle serves this purpose in a manner to beex plained, in addition to providing additional plies for these endwalls and also an additional ply for the bottom wall.

The second component for the carton construction of this invention isshown in knock-down blank form in Fig. 5, and is identified by thenumeral 50. It is generally quite similar to the blank shown in Fig. 3,being composed of a foldably connected linear series of relativelyfoldable panels 51, 52, 53, 54, 55, 56, and 57, separated by score lines58. Between panels 52 and 53,- and likewise between panels 55 and 56,there is provided a small bridging portion 59 and 60, respectively,which permits the adjacent panels to be assembled into spaced parallelrelationship so that it may embrace the end walls defined by the fiaps31 of the first component. Each of the panels 52, 53, 55, and 56 areprovided with a cut-out 61. These are located on either side of therespective bridging portions 59 and 60 in such fashion that they will bein registration when arranged in spaced parallel relationship. Thecentermost panel 54 is provided with a pair of intersecting slits 62 and63 which are normally disposed. Flap or tab 64 extends axially from thepanel 51 and is foldably secured thereto by a score line 65. The flap 64is smaller than the panel 51 and is provided with cut-outs 66 whichdefine shoulders 67 to provide a self-locking feature. The flap 64 isfurther provided with a notch 68 in its outermost free edge inalignment'with the slit 63. A similar fiap or tab '70 extends axiallyfrom the opposite panel 57 and is foldably secured thereto by a scoreline 71. It is provided with cut-outs 72 which define shoulders 73. Theoutermost edge of the flap 70 is provided with a slit 74 in alignmentwith slit 63.

The blank just described is combined with the element shown in Fig. 4 ina manner illustrated in Fig. 6. Thus, the panels 53 and 55 are foldedupwardly about fold lines 58 into perpendicular relationship with thepanel 54. In this fashion, the panel 54 may be inserted down within theconfines of the upstanding walls of the first component, and with theslit 63 fitting down over the partition defined by the flaps 40 and 46.Next, the panels 52 and 56 are folded downwardly about the respectiveend walls (flaps 31) so that the latter will be embraced by the spacedupper edge-connected panels 55 and 56 and panels 52 and 53. Next, thepanels 51 and 57 are folded reversely into abutting relationship withthe lowermost ply of the bottom wall defined by panels 21 and 27,whereupon the flaps 64 and 70 may be inserted upwardly through the slits62, 44, 49, and 30. The notches 68 and 74' will engage the partitionplies composed of flaps 40 will be composed of two plies.

4- and 46 and thereby interfit to provide partitions which are normallydisposed.

The location of the hereinbefore mentioned shoulders 67, 73, 43, and 48is adjusted by the dimension of the cut-outs 66, 72, 42, and 47 which ischosen to conform to the total thickness of the plies of the bottomwall, and, further, the shoulders are provided with a lateral dimensionselected to cooperate with the linear dimension of the slits so that thetabs or flaps will fit through the slits and will be frictionallycontacted thereby so that the carton when finally erected will-beself-locked.

In this final form, the bottom wall of the carton construction will becomposed of four plies of the material of construction, as will the endwalls, while the side walls The cut-outs 61 will register with thenotches 35 so that the hand hold will be complete through the entirethickness of the end wall.

From the foregoing description, it is obvious that the blanksconstituting the individual components of the carton of this inventionare of relatively simple design, and the folding of these blanks and thecombining thereof may be accomplished in a simple and expedient fashion.The carton construction of this invention does not require any auxiliarystiffening. elements ofwood or metal. Further, the carton of thisinvention does not require any auxiliary fastening arrangements to holdit in its'erected form. Additionally, it may be pointed out that the carton of this invention isreadily assembled by hand; The uniquefunctioning and cooperative relationship of the end flaps or tabs whichserve as integral partitioning means, and likewise serve to lockthe-structure in:its final form, provide the foregoing mentionedadvantages. Whatever weakness in the individual panels which is in.-duced by the intersecting slits in the panels forming the bottom wall isovercome by the fact that the preferred design utilizes four plies toconstitute the bottom wall. Also, whatever weakness might be induced bythe hand hold cut-outs is more than overcome by the provisionof four-plyconstruction in these end'walls. It may further be noted that the cartonis so designed that, where corrugated board is used as the material ofconstruction, the direction of the corrugations in the various pliesvaries, thus, further enhancing the strength characteristics of thecarton construction of the invention. While, as. indicated, theconstruction disclosed does not require any auxiliary fastening, it maybe desirable under the most rigorous of conditions to employ anadhesiveto bond the entire wall formers together, as well as the bottom lies. I

P It will be evident to those skilled in the art that certainmodifications may be resorted to-in connection with the cartonconstruction described without departing from the spirit and scope ofthe invention, and it is not intended by the foregoing description to belimited to the precise embodiment shown, except as indicated bythe-scope of the appended claims.

I claim:

1. A carton construction comprising an open-topped receptacle whichincludes a bottom wall, walls upstanding from the perimeter of saidbottom wall, an internal upstanding partition, said bottom wall and saidpartition each being provided with a slit, said slits intersecting inthe base of said receptacle, and a reinforcing element assembled withsaid receptacle formed of realtively stifi, sheet-like material, saidelement comprising. a central panel provided with a pair ofintersectingslots, one receiving said partition and allowing the panelto assume flush relationship with said bottom wall and the otherregistering with said slit in said bottom wall of said'receptacle, apair of relatively foldablepanels foldably secured in series to an edgeof said central panel, said panelsi being as: sembled to lie in spacedparallelism embracingoneof said upstanding walls of said receptacle, athird panel foldably secured to the second panel of saidipairspanningthe distance between the upstanding wall and the slit in said bottomwall, and thereby reinforcing said bottom wall, and a flap foldablysecured to said third panel projecting upwardly through in said slitwithin said receptacle as a second partition, and being provided with anotch in its outermost free edge engaging said first-mentionedpartition.

2. A carton construction comprising an open-topped receptacle whichincludes a bottom wall, upstanding opposed side walls, upstandingopposed end walls formed by in-turned fiaps foldably secured to saidside walls, said flaps meeting edge-to-edge to complete said end wall,and being provided with notches in said meeting edges, which notchestogether define a hand hold in said end walls, an internal upstandingpartition, said bottom wall and said partition each being provided witha slit, said slits intersecting in the plane of said bottom wall, and areinforcing element assembled with said receptacle and being formed ofrelatively stiff, sheet-like material, said element comprising a centralpanel provided with a pair of centrally located normally disposedintersecting slots, one of said slots registering with said partitionwhen said central panel is lowered thereover into flush contact withsaid bottom wall, and the other slot being adapted to register with saidslit in said bottom wall, a pair of relatively foldable panels foldablysecured in series to an edge of said central panel, said pair beingpositioned in spaced parallelism embracing one of said upstanding endwalls, a third panel foldably secured to the second panel of said pairspanning the distance between the upstanding wall and the slit in saidbottom Wall, and thereby reinforcing said bottom wall, a flap foldablysecured to said third panel projecting upwardly within said slit, andshoulders on said flap engaging said slits and preventing removalthereof, said flap being provided with a notch on its outermost freeedge engaging said partition in interfitting normal relationship tothereby further divide said receptacle into a plurality of compartments.

3. A carton having a bottom wall and walls upstanding about theperimeter of said bottom formed of multiple plies of relatively stiff,sheet-like material and having a plurality of internal partitionsupstanding from said bottom wall, said carton comprising in combination:a first member formed of said material and composed of a linear seriesof relatively foldable, generally rectangular panels in which thecentermost panel defines one of the bottom plies and is provided with apair of intersecting slits, the next two intermediate panels on bothsides of said centermost panel positioned in flush relationship witheach other to form a first pair of opposed side Walls of said carton,the next outward panel being folded reversely beneath said centermostpanel to form half of another bottom ply, and the endmost panels of saidseries projecting upwardly through said slits to form abuttingupstanding partitions, laterally projecting flaps on both sides of saidintermediate panels forming a second pair of opposed side walls, theendmost and adjacent intermediate panels having a common slot traversingthe fold line therebetween registering with said other slit in assembledformation, said flaps being respectively provided with notches in theiroutward free edges to serve as hand holds; a second member formed ofsaid material and being composed of a linear series of relativelyfoldable, generally rectangular panels in which the centermost paneldefines the top ply of said bottom wall and has a pair of intersectingslits registering with said slits in said first member when said twocentermost panels are in assembled relationship, the next twointermediate panels on both sides of said centermost panel being foldedinto spaced, parallel relationship embracing said fiaps forming a pairof opposed side walls and each having hand hold notches thereinregistering with said hand holds in said flaps, the next outward panelseach forming half of another bottom ply of said bottom wall, and theendmost panels of said series being assembled in flush abutmentprojecting upwardly through the unoccupied slit, and each being providedwith a slot in the outer free edge thereof to engage the first-mentionedpartition to thereby yield an interlocked, internally partitioned cartonwith all elements thereof formed of multiple plies.

4. A carton construction characterized by having a bottom wall andupstanding side and end walls formed of relatively stiff, sheet-likematerial, and further characterized by compartmentation, saidconstruction comprising: a first element formed of said material slittedand scored so as to define a central rectangular panel forming a bottomwall ply, and being provided with a pair of intersecting slits, a seriesof relatively foldable panels foldably secured to opposite edges of saidcentral panel, each of said series comprising a first and second panelfolded into abutment with each other in a plane normal to said centralpanels to form a two-ply side wall for said carton, and a panel foldablysecured to said second panel forming one-half of an additional bottomwall ply, a flap foldably secured to said last-mentioned panel of saidseries receivable in one of said slits and projecting upwardlytherethrough into a position normal to said bottom wall and in spacedparallelism with said side walls, said flaps and the adjacent panel towhich attached being provided with a slot crossing the line ofattachment of said flap and panel and located so that the portion of theslot in the panel registers with the remaining slit not occupied by saidflap, and flaps extending from opposite ends of one of said first andsecond panels, folded inwardly into a plane normal to said side wallsand bottom wall to together span the distance between said side walls,said flaps having notches in their outermost free edge which define ahand hold; a second element formed of said material slitted and scoredas to define a central rectangular panel provided with a pair ofintersecting slits, said central panel of said second element overlyingsaid central panel of said first element to form an inner ply of saidbottom wall, a series of relatively foldable panels foldably secured toopposite edges of said central panel, each of said series comprising afirst and second panel assembled to embrace the flaps of said firstelement forming the said end walls, to thereby yield multiple ply endwalls, each of said panels being provided with notches positioned so asto register with each other and with the notches in said flaps, a panelfoldably secured to said second panel forming one-half of an outer plyof said bottom wall, and a flap foldably secured to said last-mentionedpanel projecting upwardly through one of said slits and being providedwith a notch in its outer free edge for interfitting with said partitionmember formed of said first element.

References Cited in the file of this patent UNITED STATES PATENTS2,089,067 Myers Aug 3, 1937

